Electric motor, air conditioner, and electric apparatus

ABSTRACT

A power-supply-lead retaining part includes a pair of legs extending toward a bearing through hole, a pair of first locking portions provided on the pair of legs and locked to the edge portion of the bearing through hole, and a pair of second locking portions locked to the edge portion of the sensor substrate on both sides of a notch.

FIELD

The present invention relates to a stator, an electric motor, and an airconditioner.

BACKGROUND

Conventional molded electric motors are configured such that asensor-lead board-in connector is attached to one surface of a sensorsubstrate, sensor leads are routed via the sensor-lead board-inconnector, a power-supply-lead board-in connector is attached to theother surface of the sensor substrate, and power supply leads are routedvia the power-supply-lead board-in connector (for example, PatentLiterature 1).

CITATION LIST Patent Literature

Patent Literature 1: Japanese Patent Application Laid-open No.2007-228667

SUMMARY Technical Problem

The sensor substrate that is used can have a shape having a bearingthrough hole other than the crescent shape that is applied to theconventional electric motor described in Patent Literature 1.

The present invention has been achieved in view of the above and anobject of the present invention is to provide a molded stator, a moldedelectric motor, and an air conditioner including a lead lead-out portionhaving a structure that is applied to the sensor substrate provided witha bearing through hole, that is easy to assemble, and that reduces thecosts.

Solution to Problem

In order to solve the above problems and achieve the object, a statoraccording to an aspect of the present invention includes: a sensorsubstrate attached to one end of a stator core in an axial direction ofthe stator core, the sensor substrate being provided with a bearingthrough hole for allowing a bearing of a rotor to pass and beingprovided with a notch on a periphery, the notch being used for leadingout a lead; and a lead retaining part attached to the sensor substrateand retaining the lead, wherein the lead retaining part includes a pairof legs extending toward the bearing through hole, a pair of firstlocking portions provided on the pair of legs and locked to an edgeportion of the bearing through hole, and a pair of second lockingportions locked to an edge portion of the sensor substrate on both sidesof the notch.

Advantageous Effects of Invention

According to the present invention, an effect is obtained where it ispossible to obtain a lead lead-out portion having a structure that iseasy to assemble and that reduces the costs.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view illustrating the configuration of a statorassembly of an electric motor according to a first embodiment.

FIG. 2 is a plan view illustrating the configuration of a sensorsubstrate.

FIG. 3 is a diagram illustrating how a power-supply-lead board-inconnector is attached to the sensor substrate.

FIG. 4 is a diagram illustrating how a substrate pressing part isattached to the sensor substrate.

FIG. 5 is a diagram illustrating how a sensor-lead board-in connector isattached to the sensor substrate.

FIG. 6 is a diagram illustrating the configuration of apower-supply-lead retaining part.

FIG. 7 is a diagram illustrating the configuration of a lead lead-outpart.

FIG. 8 is a diagram illustrating how the power-supply-lead retainingpart is attached to the sensor substrate.

FIG. 9 is a diagram illustrating the configuration of a sensor-leadretaining part.

FIG. 10 is a diagram illustrating how the lead lead-out part is attachedto the sensor substrate.

FIG. 11 is a diagram illustrating the sensor substrate on which leadsare routed.

FIG. 12 is a perspective view illustrating how the sensor substrate onwhich leads are routed is attached to the stator.

FIG. 13 is a perspective view illustrating a molded stator.

FIG. 14 is a longitudinal cross-sectional view illustrating theconfiguration of a molded electric motor.

FIG. 15 is a diagram illustrating an example of the configuration of anair conditioner according to a second embodiment.

DESCRIPTION OF EMBODIMENTS

Exemplary embodiments of a stator, an electric motor, and an airconditioner according to the present invention will be explained belowin detail with reference to the drawings. This invention is not limitedto the embodiments.

First Embodiment

FIG. 1 is a perspective view illustrating the configuration of a statorassembly of an electric motor according to the present embodiment; FIG.2 is a plan view illustrating the configuration of a sensor substrate;FIG. 3 is a diagram illustrating how a power-supply-lead board-inconnector is attached to the sensor substrate; FIG. 4 is a diagramillustrating how a substrate pressing part is attached to the sensorsubstrate; FIG. 5 is a diagram illustrating how a sensor-lead board-inconnector is attached to the sensor substrate; FIG. 6 is a diagramillustrating the configuration of a power-supply-lead retaining part;FIG. 7 is a diagram illustrating the configuration of a lead lead-outpart; FIG. 8 is a diagram illustrating how the power-supply-leadretaining part is attached to the sensor substrate; FIG. 9 is a diagramillustrating the configuration of a sensor-lead retaining part; FIG. 10is a diagram illustrating how the lead lead-out part is attached to thesensor substrate; FIG. 11 is a diagram illustrating the sensor substrateon which leads are routed; FIG. 12 is a perspective view illustratinghow the sensor substrate on which leads are routed is attached to thestator; FIG. 13 is a perspective view illustrating a molded stator; andFIG. 14 is a longitudinal cross-sectional view illustrating theconfiguration of a molded electric motor. The molded stator and themolded electric motor according to the present embodiment will bedescribed below with reference to FIG. 1 to FIG. 14.

A stator assembly 60 includes an annular stator 61; a sensor substrate 1attached to the stator 61 at one end in the axial direction of thestator 61; a substrate pressing part 6, which is attached to the sensorsubstrate 1 and presses on the surface of the sensor substrate 1 on thecounter-stator side; a power-supply-lead board-in connector 4 attachedto the surface of the sensor substrate 1 on the counter-stator side; asensor-lead board-in connector 5 attached to the surface of the sensorsubstrate 1 on the counter-stator side in a similar manner to thepower-supply-lead board-in connector 4; power supply leads 2 connectedto the power-supply-lead board-in connector 4; sensor leads 3 connectedto the sensor-lead board-in connector 5; a lead lead-out part 8, whichleads out the power supply leads 2 and the sensor leads 3; apower-supply-lead retaining part 7, which is attached to the sensorsubstrate 1 and the lead lead-out part 8 and retains the power supplyleads 2 together with the lead lead-out part 8; and a sensor-leadretaining part 9, which is attached to the power-supply-lead retainingpart 7 and retains the sensor leads 3 together with the lead lead-outpart 8 (FIG. 1). “Counter-stator side” means the side opposite to thestator side. In the following, “radial direction” means the radialdirection of the stator and “axial direction” means the axial directionof the stator.

The stator 61 includes a stator core 62, which is formed by laminating,realized by crimping, welding, bonding, or the like, magnetic steelsheets that are stamped into strips; an insulating portion 63, which isprovided on the stator core 62 by molding a thermoplastic resin, such asPBT (polybutylene terephthalate), such that it is integral with thestator core 62 or by attaching the molded thermoplastic resin to thestator core 62; and coils 68, which are magnet wires wound around theinsulating portion 63 provided on teeth 67. The sensor substrate 1 isattached to the stator core 62 at one end in the axial direction of thestator core 62.

The insulating portion 63 includes a plurality of pins 64, to which thesensor substrate 1 is attached; a hole into which a neutral pointterminal 65 is inserted; and a plurality of holes into which powersupply terminals 66 are inserted. The neutral point terminal 65 isformed by stamping out and bending a plate. The neutral point terminal65 includes two hook portions onto which one end of each of the magnetwires is hooked and it is attached by being inserted into the hole forthe neutral point terminal provided in the insulating portion 63. Thepower supply terminals 66 are formed by bending rectangular wires. Thepower supply terminals 66 are attached by being inserted into the holesfor the power supply terminals provided in the insulating portion 63.The other ends of the magnet wires are hooked onto the hook portions ofthe power supply terminals 66 and are bonded to the hook portions byfusing or soldering. The stator 61 is obtained by bending thestrip-shaped core, from which the stator core 62 around which the coils68 are wound is configured, into an annular shape and then welding theabutting portions (not illustrated) together.

In the present embodiment, the stator 61 is formed by, after the coils68 are wound around the magnetic steel sheets that are stamped intostrips, shaping the strips into an annular shape; however, the statorcore 62 obtained by stamping magnetic steel sheets into an annular shapecan also be used.

FIG. 2 illustrates the surface of the sensor substrate 1 on thecounter-stator side. The sensor substrate 1 has a doughnut shape(annular shape). A board-in-connector disposing portion 10, on which thepower-supply-lead board-in connector 4 is disposed, and aboard-in-connector disposing portion 11, on which the sensor-leadboard-in connector 5 is disposed, are provided on the surface of thesensor substrate 1 on the counter-stator side. A rotation detectioncircuit that includes hole ICs 12 for detecting rotation of the rotor ofthe electric motor is provided on the surface of the sensor substrate 1on the stator side. A power-supply wiring pattern is formed across bothsurfaces of the sensor substrate 1.

A notch 13 for leading out leads is provided on a peripheral portion ofthe sensor substrate 1. The peripheral portion becomes a lead lead-outportion. The notch 13 has, for example, a rectangular shape. In thesensor substrate 1, notches 14 are provided, which further notch bothcorner portions of the notch 13 on the inner diameter side of the notch13 (bearing through hole 15 side). In other words, both ends of thenotch 13 on the inner diameter side are further notched so as to formthe notches 14. Both ends indicate both ends in the direction orthogonalto the radial direction. The notches 14 each have, for example, asemi-circular shape. The notches 14 are formed for the power supplyleads 2 to escape therethrough. When the sensor leads 3 are laid on thesensor substrate 1, the power supply leads 2 protrude outwardly relativeto the sensor leads 3 in the peripheral direction.

The bearing through hole 15 having a circular shape is provided, forexample, at the central position of the sensor substrate 1. The bearingthrough hole 15 is a hole for allowing a bearing 103 (FIG. 14) of arotor 101 to pass. The lead lead-out portion side of the bearing throughhole 15 is notched, for example, into a rectangular shape. In otherwords, a notch 16, which communicates with the bearing through hole 15,is provided on the lead lead-out portion side (the notch 13 side) of thebearing through hole 15 in the sensor substrate 1. The notch 16 can beregarded as part of the bearing through hole 15. It is satisfactory ifthe sensor substrate 1 has a shape provided with the bearing throughhole 15 and the sensor substrate 1 may have a shape other than adoughnut shape.

The board-in-connector disposing portion 11 is disposed between thenotch 16 and the notch 13 of the sensor substrate 1. Theboard-in-connector disposing portion 10 is provided such that it facesthe board-in-connector disposing portion 11 with the bearing throughhole 15 therebetween.

A plurality of pin through holes 18 and a plurality of terminal throughholes 19 are provided in the peripheral portion of the sensor substrate1. The pin through holes 18 are holes into which the pins 64 of theinsulating portion 63 are inserted (FIG. 12). The terminal through holes19 are holes into which the power supply terminals 66 are inserted (FIG.12). A plurality of pin through holes 17 are formed in the sensorsubstrate 1. When the substrate pressing part 6 is attached to thesensor substrate 1, pins 26 (FIG. 4) provided on the substrate pressingpart 6 are inserted into the pin through holes 17. Furthermore, a notch20 is formed on the periphery of the sensor substrate 1. When thesubstrate pressing part 6 is attached to the sensor substrate 1, a leg29 (FIG. 4) provided on the substrate pressing part 6 is fitted into thenotch 20.

In FIG. 3, the power-supply-lead board-in connector 4 is disposed on theboard-in-connector disposing portion 10, the terminals (not illustrated)that are exposed from the surface of the sensor substrate 1 on thestator side are soldered, and the power supply leads 2 are connected tothe power-supply-lead board-in connector 4. Thus, the sensor substrate 1and the power supply leads 2 are connected together via thepower-supply-lead board-in connector 4. The power supply leads 2 includepower supply leads 2 a to 2 c.

As illustrated in FIG. 4, the power supply leads 2 are routed such thatthey are separated into one lead (the power supply lead 2 a) and twoleads (the power supply leads 2 b and 2 c). Specifically, the powersupply leads 2 are routed by attaching the substrate pressing part 6 tothe sensor substrate 1 such that one of the three leads (the powersupply lead 2 a) is routed clockwise around the bearing through hole 15and the remaining two leads (the power supply leads 2 b and 2 c) arerouted counterclockwise around the bearing through hole 15. The powersupply leads 2 may be routed such that one of the three leads (the powersupply lead 2 a) is routed counterclockwise around the bearing throughhole 15 and the remaining two leads (the power supply leads 2 b and 2 c)are routed clockwise around the bearing through hole 15.

The substrate pressing part 6 includes a plurality of substrate pressingprojections 25 disposed on the sensor substrate 1; the pins 26 insertedinto the pin through holes 17 in the sensor substrate 1; and aconnection part 27, which connects the substrate pressing projections 25and the pins 26 together. The substrate pressing projections 25 extendtoward the sensor substrate 1 and the end surfaces of the substratepressing projections 25 are in contact with the surface of the sensorsubstrate 1. There are, for example, six substrate pressing projections25. There are, for example, three pins 26. The connection part 27 is,for example, shaped as a thin plate.

Each of the substrate pressing projections 25 also includes a projectionextending to the counter-stator side. The end surfaces of theprojections become a mold contact surface when molding is performed. Ina similar manner, each of the pins 26 includes a projection extending tothe counter-stator side. The end surfaces of the projections become amold contact surface when molding is performed.

The substrate pressing part 6 is provided with, at portions that aredisposed on the periphery of the sensor substrate 1 when the substratepressing part 6 is disposed on the sensor substrate 1, a plurality ofpin through holes 28 and the leg 29, which is hooked onto the peripheryof the sensor substrate 1. In a state where the substrate pressing part6 is disposed on the sensor substrate 1, the pin through holes 28communicate with the pin through holes 18 and the pins 64 of theinsulating portion 63 are inserted into the pin through holes 28. Thereare three pin through holes 28 to correspond to the number of the pinthrough holes 18.

A plurality of (five in the example in FIG. 4) substrate pressingprojections 25 are disposed on the periphery of the bearing through hole15. The power supply leads 2 are guided by the substrate pressingprojections 25 and are routed around the periphery of the bearingthrough hole 15. Thus, the power supply leads 2 can be prevented fromsagging into the bearing through hole 15.

Insertion of the pins 26 of the substrate pressing part 6 into the pinthrough holes 17 in the sensor substrate 1 can prevent the substratepressing part 6 from being deformed because of the restoring force ofthe power supply leads 2 and thus the power supply leads 2 can be routedto the predetermined position. Therefore, the manufacturing quality isimproved.

The tip portions of the pins 26 that are exposed from the hole ICmounted surface of the sensor substrate 1 by inserting the pins 26 intothe pin through holes 17 are thermally welded or bonded; therefore, thesubstrate pressing part 6 can be prevented from moving in the axialdirection (axial direction of the stator 61) and thus the power supplyleads 2 can be prevented from being removed. Therefore, the quality canbe further improved.

Moreover, as will be described later, when the stator assembly 60 ismolded, the end surfaces of the projections of the substrate pressingprojections 25 and the pins 26 extending to the counter-stator side arebrought into contact with the mold; therefore, the sensor substrate 1can be prevented from being deformed because of the resin pressureduring molding and thus the power supply leads 2 can be prevented frombeing displaced in the axial direction because of the connection part27. Therefore, the quality can be improved.

Next, as illustrated in FIG. 5, the sensor-lead board-in connector 5 isdisposed on the board-in-connector disposing portion 11 of the sensorsubstrate 1 and the terminals that are exposed from the surface of thesensor substrate 1 on which the hole ICs 12 are mounted are soldered.Thus, the rotation detection circuit of the sensor substrate 1 and thesensor leads 3 are connected together via the sensor-lead board-inconnector 5. At this point, the power supply leads 2 are routed, byusing the substrate pressing part 6, to bypass the bearing through hole15 such that the power supply leads 2 are separated into the powersupply lead 2 a and the power supply leads 2 b and 2 c; therefore, aspace is ensured between the power supply lead 2 a and the power supplyleads 2 b and 2 c. Accordingly, the sensor leads 3 can be routed betweenthe power supply lead 2 a and the power supply leads 2 b and 2 c. Thus,the attaching process of the sensor leads 3 to the sensor-lead board-inconnector 5 is facilitated. Therefore, the manufacturing cost is reducedand the manufacturing quality is improved.

Typically, routing of the power supply leads 2 and the sensor leads 3 tothe sensor substrate 1 is facilitated by using a board-in connector.However, when the routing space between the bearing through hole 15 andthe periphery is limited because of a restriction on the size or thelike of the sensor substrate 1, it is difficult in some cases tocollectively route all of the three power supply leads 2. In such acase, as described in the present embodiment, the power supply leads 2are separated into two groups and then routed. This enables routing ofthe power supply leads 2. When the routing space is not limited, all ofthe three power supply leads 2 may be collectively routed clockwise orcounterclockwise such that they bypass the bearing through hole 15without separating the power supply leads 2.

The rotation detection circuit including the hole ICs 12 is provided onthe sensor substrate 1; therefore, it is difficult in some cases todispose the power-supply-lead board-in connector 4 on the surface of thesensor substrate 1 on the stator side and route the power supply leads2. In such a case, the present embodiment is useful. That is, both thepower-supply-lead board-in connector 4 and the sensor-lead board-inconnector 5 are disposed on the surface of the sensor substrate 1 onwhich the hole ICs are not mounted (surface on the counter-stator side),and the sensor-lead board-in connector 5 is disposed between the leadlead-out portion (the notch 13) and the bearing through hole 15 toshorten the path along which the sensor leads 3 are routed, i.e., toprevent the sensor leads 3 from being routed along the bearing throughhole 15, thereby enabling the power supply leads 2 and the sensor leads3 to be routed.

Furthermore, in the present embodiment, the power-supply-lead board-inconnector 4 is disposed between the bearing through hole 15 and theperiphery on the side opposite to the lead lead-out portion of thesensor substrate 1; therefore, distribution of the power supply leads 2is balanced (except for the difference in number) with respect to thesensor-lead board-in connector 5. Thus, attaching of the sensor-leadboard-in connector 5 is facilitated compared with the case where thepower-supply-lead board-in connector 4 is disposed in a differentlocation. Therefore, the manufacturing cost is reduced and themanufacturing quality is improved.

FIG. 6(a) is a plan view of the power-supply-lead retaining part 7 whenviewed from the stator side; FIG. 6(b) is a side view of thepower-supply-lead retaining part 7; and FIG. 6(c) is a plan view of thepower-supply-lead retaining part 7 when viewed from the counter-statorside. FIG. 8(a) is a plan view of the sensor substrate 1 to which thepower-supply-lead retaining part 7 is attached when viewed from thestator side and FIG. 8(b) is a side view illustrating how the leadlead-out part 8 is attached to the power-supply-lead retaining part 7.As illustrated in FIG. 8, the power-supply-lead retaining part 7 isattached to the lead lead-out portion of the sensor substrate 1.

The power-supply-lead retaining part 7 includes a base portion 7 a,which is a power-supply-lead retaining portion; a pair of lockingportions 7 b, which are locked to the edge portions of the sensorsubstrate 1 on both sides of the notch 13; a pair of attaching legs 7 cfor attaching the sensor-lead retaining part 9; a pair of legs 7 d,which extend toward the bearing through hole 15; a pair of lockingportions 7 e, which are locked to the edge portion of the bearingthrough hole 15; a pair of core-metal-end-surface contact portions 7 h,on which the core-metal end surface of a mold is disposed; and a pair ofattaching portions 7 g for attaching the lead lead-out part 8.

The base portion 7 a is planar and includes three grooves 7 f forretaining the power supply leads 2 on the surface on the counter-statorside.

The locking portions 7 b are respectively provided on both ends of thebase portion 7 a on the inner diameter side (the bearing through hole 15side). Specifically, the locking portions 7 b are provided such thatthey protrude outwardly from the both ends, respectively. Both ends ofthe base portion 7 a indicate both ends in the direction orthogonal tothe radial direction. The locking portions 7 b come into contact withthe edge portions of the sensor substrate 1 on both sides of the notch13. Both sides of the notch 13 indicate both sides in the directionorthogonal to the radial direction. Specifically, the locking portions 7b come into contact with both the peripheral portion of the surface ofthe sensor substrate 1 on the counter-stator side and the side surfaceportion of the sensor substrate 1 on both sides of the notch 13, andthey are locked to the edge portions of the sensor substrate 1 on bothsides of the notch 13 (FIG. 8(b)). FIG. 6(b) illustrates contactsurfaces 7 l and 7 m of the locking portions 7 b, which come intocontact with the sensor substrate 1. The contact surfaces 7 l and 7 mform an L-shaped cross section. As illustrated in FIG. 8(b), the lockingportions 7 b are configured such that the end surfaces thereof on thestator side are flush with the surface of the sensor substrate 1 on thestator side.

The attaching legs 7 c extend to the outer diameter side from thelocking portions 7 b, respectively. As will be described later, afterthe lead lead-out part 8 is attached to the power-supply-lead retainingpart 7, legs 9 c of the sensor-lead retaining part 9 are fitted into thespace between the attaching legs 7 c and the base portion 7 a, wherebythe sensor-lead retaining part 9 is attached to the power-supply-leadretaining part 7.

The legs 7 d extend toward the bearing through hole 15 respectively fromboth ends of the base portion 7 a on the inner diameter side (thebearing through hole 15 side). The locking portions 7 e are providedsuch that they are integral with, for example, the tip portions of thelegs 7 d. The locking portions 7 e are hooked and locked to the notch16, which extends in the axial direction and is provided in the bearingthrough hole 15.

The locking portions 7 b and 7 e are attached to the sensor substrate 1in such a manner, whereby the power-supply-lead retaining part 7 isattached to the sensor substrate 1.

In a state where the power-supply-lead retaining part 7 is attached tothe sensor substrate 1, substrate pressing portions 7 i, which are partsof the legs 7 d on the side on which the locking portions 7 e areprovided, are disposed on both sides of the board-in-connector disposingportion 11 and they are in contact with the surface of the sensorsubstrate 1 on the stator side and presses on the sensor substrate 1(FIG. 6(a) and FIG. 8). The locking portions 7 b and 7 e are attached tothe sensor substrate 1 and the substrate pressing portions 7 i of thelegs 7 d press on the sensor substrate 1 from the stator side;therefore, the sensor substrate 1 is sandwiched by the locking portions7 b and the substrate pressing portions 7 i. Thus, the power-supply-leadretaining part 7 can be prevented from being displaced in the axialdirection. Therefore, the manufacturing quality is improved and thus thequality of the product is improved.

In a state where the power-supply-lead retaining part 7 is attached tothe sensor substrate 1, fitting portions 7 j, which are parts of thelegs 7 d on the side on which the base portion 7 a is provided, arefitted into the notch 13 (FIG. 6(a) and FIG. 8). By fitting the fittingportions 7 j of the legs 7 d into the notch 13 of the sensor substrate1, the power-supply-lead retaining part 7 can be prevented from beingdisplaced in the direction orthogonal to the lead lead-out direction(radial direction). Therefore, the manufacturing quality is improved andthus the quality of the product is improved.

The locking portions 7 e are disposed in the notch 16, whichcommunicates with the bearing through hole 15. With this configuration,the locking portions 7 e are located such that the wiring pattern on thesensor substrate 1 is least hindered. Therefore, this configuration isuseful for routing the wiring pattern on the sensor substrate 1.

The core-metal-end-surface contact portions 7 h are provided at the tipportions of the legs 7 d. As will be described later, thecore-metal-end-surface contact portions 7 h are portions that come intocontact with the core-metal end surface of a mold for the stator 61.

The pair of attaching portions 7 g lock a pair of legs 8 d of the leadlead-out part 8. Accordingly, the lead lead-out part 8 is attached tothe power-supply-lead retaining part 7.

FIG. 7(a) is a plan view of the lead lead-out part 8 when viewed fromthe stator side, FIG. 7(b) is a side view of the lead lead-out part 8,and FIG. 7(c) is a plan view of the lead lead-out part 8 when viewedfrom the counter-stator side.

As illustrated in FIG. 7, the lead lead-out part 8 includes a planarbase portion 8 a and the pair of legs 8 d. The legs 8 d are provided onboth ends of the base portion 8 a on the inner diameter side (thebearing through hole 15 side) and extend in the axial direction andtoward the stator side.

The base portion 8 a is planar and includes a plurality of grooves 8 cfor retaining the sensor leads 3 on the surface on the counter-statorside and three grooves 8 b for retaining the power supply leads 2 on thesurface on the stator side. The number of the sensor leads 3 to be drawnout is, for example, two or more, i.e., equal to the number of thegrooves 8 c.

As illustrated in FIG. 8(b), the lead lead-out part 8 is moved in thedirection indicated by the arrow and thus the legs 8 d are fitted andlocked into the attaching portions 7 g of the power-supply-leadretaining part 7, whereby the lead lead-out part 8 is attached to thepower-supply-lead retaining part 7.

FIG. 9(a) is a plan view of the sensor-lead retaining part 9 when viewedfrom the stator side; FIG. 9(b) is a side view of the sensor-leadretaining part 9; and FIG. 9(c) is a plan view of the sensor-leadretaining part 9 when viewed from the counter-stator side. Thesensor-lead retaining part 9 includes a base portion 9 a, which is asensor-lead retaining portion, and the pair of legs 9 c.

The base portion 9 a is planar and includes a plurality of grooves 9 bfor retaining the sensor leads 3 on the surface on the stator side.

The legs 9 c are respectively provided on both ends of the base portion9 a on the inner diameter side (the bearing through hole 15 side) andeach have an L-shape that extends to the stator side and then extends tothe inner diameter side (the bearing through hole 15 side).

The legs 9 c of the sensor-lead retaining part 9 are fitted into thespace between the attaching legs 7 c and the base portion 7 a of thepower-supply-lead retaining part 7 to which the lead lead-out part 8 isattached, whereby the sensor-lead retaining part 9 is attached to thepower-supply-lead retaining part 7.

In this case, the portions of the legs 9 c extending to the innerdiameter side (the bearing through hole 15 side) press on the surface ofthe sensor substrate 1 on the stator side; therefore, the sensorsubstrate 1 can be prevented from being displaced in the axialdirection. Therefore, the manufacturing quality is improved and thus thequality of the product is improved.

As illustrated in FIG. 10, after the power supply leads 2 are routedfrom the power-supply-lead board-in connector 4 to the notches 14 forthe power supply leads to escape therethrough such that they bypass thebearing through hole 15, the power supply leads 2 pass through thenotches 14 for the power supply leads to escape therethrough, are routedbetween the legs 7 d of the power-supply-lead retaining part 7 on thestator side of the sensor substrate 1, and are retained such that theyare sandwiched between the base portion 8 a of the lead lead-out part 8and the base portion 7 a of the power-supply-lead retaining part 7 so asto be drawn out from the lead lead-out portion.

Furthermore, the sensor leads 3 are drawn out linearly in the radialdirection from the sensor-lead board-in connector 5 toward the leadlead-out portion.

The notches 14 for the power supply leads to escape therethrough aredisposed outside the range that is occupied by the sensor lead 3 group.In other words, the length between the notches 14 is larger than thewidth occupied by the sensor lead 3 group and thus the notches 14 aredisposed outside the range that is occupied by the sensor lead 3 groupin a state where the sensor lead 3 group is routed. Accordingly, thepower supply leads 2 can pass through the notches 14 without beinghindered by the sensor lead 3 group. With such a configuration, routingof the power supply leads 2 is facilitated. Therefore, the manufacturingcost is reduced.

The power supply leads 2 can be routed by setting the notch 13 in thelead lead-out portion to be larger than the width occupied by the sensorlead 3 group. However, for example, when the notch 13 cannot be madelarge because the sensor substrate 1 is small or when the lead lead-outpart 8 needs to be made as small as possible, provision of the notches14 for the power supply leads to escape therethrough is effective.

In the present embodiment, the power supply leads 2 are routed such thatthey are separated into two groups. Accordingly, the notches 14 for thepower supply leads to escape therethrough are provided on both sides ofthe notch 13 in the lead lead-out portion. However, when all of thethree power supply leads 2 are collectively routed clockwise orcounterclockwise, it is satisfactory if the notch 14 for the powersupply leads to escape therethrough is provided only on one side of thenotch 13.

As illustrated in FIG. 11, when viewed in plan from the counter-statorside, the sensor leads 3 are laid on the power supply leads 2, which arerouted to the stator side of the sensor substrate 1 via the notches 14for the power supply leads to escape therethrough. With such aconfiguration, the movement of the power supply leads 2 in the axialdirection is restricted by the sensor leads 3 in the lead lead-outportion; therefore, the power supply leads 2 can be prevented from beingexposed to the outside when molding is performed. Therefore, themanufacturing quality is improved.

Furthermore, the legs 9 c of the sensor-lead retaining part 9 are fittedinto the space between the attaching legs 7 c and the base portion 7 aof the power-supply-lead retaining part 7 by moving the sensor-leadretaining part 9 in the direction indicated by the arrow in FIG. 10,thereby attaching the sensor-lead retaining part 9 to thepower-supply-lead retaining part 7. Accordingly, the sensor leads 3 areretained such that they are sandwiched between the lead lead-out part 8and the sensor-lead retaining part 9 and the sensor leads 3 are drawnout from the lead lead-out portion.

In such a manner, attachment of the power supply leads 2 and the sensorleads 3 to the sensor substrate 1 is completed (FIG. 11).

As illustrated in FIG. 12, the sensor substrate 1 to which the powersupply leads 2 and the sensor leads 3 are attached is attached to thestator 61. When being attached, the pins 64 of the insulating portion 63are inserted into the pin through holes 18 (FIG. 2) in the sensorsubstrate 1 and the pin through holes 28 (FIG. 4) in the substratepressing part 6 so as to be positioned. When the sensor substrate 1 isdisposed, the power supply terminals 66 attached to the insulatingportion 63 are inserted into the terminal through holes 19 (FIG. 2) inthe sensor substrate 1. Then, the pins 64 exposed from the substratepressing part 6 are thermally welded (welded portions 71 in FIG. 1) andfurthermore, the power supply terminals 66 exposed from the sensorsubstrate 1 are soldered (soldered portions 70 in FIG. 1), whereby thestator assembly 60 in which the sensor substrate 1 is attachedillustrated in FIG. 1 is completed.

FIG. 13 illustrates the outline of a molded stator 100. The moldedstator 100 is obtained by setting the stator assembly 60 (FIG. 1) in amold and molding the molded stator 100 from a mold resin, such as BMC(Bulk Molding Compound). In other words, the molded stator 100 includesa mold resin portion 90 covering the stator 61.

When the stator assembly 60 is set in the mold, thecore-metal-end-surface contact portions 7 h provided on the legs 7 d ofthe power-supply-lead retaining part 7 come into contact with the endsurface of the metal core of the mold and moreover the end surfaces ofthe projections of the substrate pressing projections 25 and the pins 26of the substrate pressing part 6 extending to the counter-stator sidecome into contact with the end surface of the mold that is opposite tothe openings of the mold. Accordingly, the sensor substrate 1 can beprevented from being deformed because of the resin pressure duringmolding. Therefore, the quality can be improved.

FIG. 14 illustrates the configuration of a molded electric motor 200 incross section. The molded electric motor 200 includes the rotor 101,which includes a shaft 102; the bearings 103 attached to the shaft 102;the molded stator 100; and a bracket 104 press-fitted into the moldedstator 100. FIG. 14 also illustrates components of the molded stator100, such as the stator 61 and the sensor substrate 1. In the presentembodiment, an explanation has been given of the molded stator 100 andthe molded electric motor 200; however, the present embodiment can beapplied to the stator 61 that is not molded and an electric motor thatincludes the stator 61 that is not molded.

As described above, according to the present embodiment, thepower-supply-lead retaining part 7 includes the pair of legs 7 d, whichextend toward the bearing through hole 15; the pair of locking portions7 e provided on the pair of legs 7 d and locked to the edge portion ofthe bearing through hole 15; and the pair of locking portions 7 b, whichare locked to the edge portions of the sensor substrate 1 on both sidesof the notch 13.

With such a configuration, the power-supply-lead retaining part 7 can beeasily attached to the sensor substrate 1. Therefore, it is possible toobtain a lead lead-out portion having a structure that is easy toassemble and that reduces the costs.

In the present embodiment, the power-supply-lead retaining part 7includes the pair of legs 7 d, the pair of locking portions 7 e, and thepair of locking portions 7 b; however, the sensor-lead retaining part 9may include the pair of legs 7 d, the pair of locking portions 7 e, andthe pair of locking portions 7 b. Moreover, in the present embodiment,the pair of legs 7 d, the pair of locking portions 7 e, and the pair oflocking portions 7 b are provided; however, the configuration may besuch that only any one of the legs 7 d of the pair, only any one of thelocking portions 7 e of the pair, and only any one of the lockingportions 7 b of the pair are provided.

The structure of the power-supply-lead retaining part 7 is applied tothe sensor substrate 1 that includes the bearing through hole 15 and thenotches 13 and 16, and this structure can be applied regardless of thelocations at which the power-supply-lead board-in connector 4 and thesensor-lead board-in connector 5 are disposed. For example, even whenthe power-supply-lead board-in connector 4 is disposed on the surface ofthe sensor substrate 1 on the stator side and the sensor-lead board-inconnector 5 is disposed on the surface of the sensor substrate 1 on thecounter-stator side, the above structure can be applied as long as thepower supply leads 2 and the sensor leads 3 can be routed.

Moreover, in the present embodiment, the sensor substrate 1 providedwith the bearing through hole 15 is attached to one end of the stator61; the sensor-lead board-in connector 5 is disposed between the bearingthrough hole 15 and the notch 13 on the surface of the sensor substrate1 on the counter-stator side; and the power-supply-lead board-inconnector 4 is disposed at a position facing the sensor-lead board-inconnector 5 with the bearing through hole 15 therebetween on the surfaceof the sensor substrate 1 on the counter-stator side.

With such a configuration, even when the outer diameter of the stator 61is small and the size of the sensor substrate 1 is restricted, and thus,for example, it is difficult to dispose the power-supply-lead board-inconnector 4 on the surface of the sensor substrate 1 on the stator side,the power supply leads 2 and the sensor leads 3 can still be routed.

Furthermore, the sensor leads 3 are routed linearly to the lead lead-outportion, whereas the power supply leads 2 are routed such that theybypass the bearing through hole 15; therefore, routing of the powersupply leads 2 and the sensor leads 3 is facilitated.

Therefore, according to the present embodiment, routing is facilitated,the costs are reduced, and lead routing is realized that can be appliedregardless of the outer diameter of the stator.

Other effects of the present embodiment are as already described withthe description of the configuration.

Lead routing inclusive of the structure of the lead lead-out portiondescribed in the present embodiment can also be applied to theconfiguration in which a stator is not molded. In other words, thepresent embodiment can also be applied to a stator that is not moldedand an electric motor that includes the stator that is not molded.Furthermore, it is possible to provide electric apparatuses in whichsuch an electric motor is installed.

Second Embodiment

FIG. 15 is a diagram illustrating an example of the configuration of anair conditioner according to the present embodiment. An air conditioner210 according to the present embodiment includes an indoor unit 201 andan outdoor unit 202 connected to the indoor unit 201. The outdoor unit202 includes an air blower in which a molded electric motor 200 a isinstalled. The indoor unit 201 also includes an air blower in which amolded electric motor 200 b is installed. The molded electric motors 200a and 200 b are both molded electric motors described in the firstembodiment.

According to the present embodiment, by installing, in the airconditioner 210, the electric motor in the first embodiment, which islow in cost, is of good quality, is easily routed, and realizes easylead routing, the cost of the air conditioner 210 can be reduced and thequality of the air conditioner 210 can be improved.

The electric motor in the first embodiment can also be installed inelectric apparatuses other than the air conditioner. Even in such acase, effects similar to those in the present embodiment can beobtained.

INDUSTRIAL APPLICABILITY

The present invention is useful as a stator, an electric motor, and anair conditioner.

REFERENCE SIGNS LIST

1 sensor substrate, 2, 2 a to 2 c power supply lead, 3 sensor lead, 4power-supply-lead board-in connector, 5 sensor-lead board-in connector,6 substrate pressing part, 7 power-supply-lead retaining part, 7 a baseportion, 7 b, 7 e locking portion, 7 c attaching leg, 7 d leg, 7 fgroove, 7 g attaching portion, 7 h core-metal-end-surface contactportion, 7 i substrate pressing portion, 7 j fitting portion, 7 l, 7 mcontact surface, 8 lead lead-out part, 8 a base portion, 8 b, 8 cgroove, 8 d leg, 9 sensor-lead retaining part, 9 a base portion, 9 bgroove, 9 c leg, 10, 11 board-in-connector disposing portion, 12 holeIC, 13, 14, 16, 20 notch, 15 bearing through hole, 17, 18, 28 pinthrough hole, 19 terminal through hole, 25 substrate pressingprojection, 26 pin, 27 connection part, 29 leg, 60 stator assembly, 61stator, 62 stator core, 63 insulating portion, 64 pin, 65 neutral pointterminal, 66 power supply terminal, 67 teeth, 68 coil, 70 solderedportion, 71 welded portion, 90 mold resin portion, 100 molded stator,101 rotor, 102 shaft, 103 bearing, 104 bracket, 200, 200 a, 200 b moldedelectric motor, 201 indoor unit, 202 outdoor unit, 210 air conditioner.

1. An electric motor comprising: a sensor substrate attached to one endof a stator core in an axial direction of the stator core, the sensorsubstrate being provided with a bearing through hole for allowing abearing of a rotor to pass and being provided with a notch on aperiphery, the notch being used for leading out a lead; and a leadretaining part attached to the sensor substrate and retaining the lead,wherein the lead retaining part includes a leg extending toward thebearing through hole, a first locking portion provided on the leg andlocked to an edge portion of the bearing through hole, and a secondlocking portion locked to an edge portion of the notch.
 2. The electricmotor according to claim 1, wherein the leg includes a substratepressing portion that comes into contact with a surface on a stator coreside of the sensor substrate and presses on the surface.
 3. The electricmotor according to claim 2, wherein the leg includes a fitting portionthat is fitted into the notch.
 4. The electric motor according to claim3, wherein the lead is a power supply lead, the lead retaining part is apower-supply-lead retaining part, the notch is used also for leading outa sensor lead, a sensor-lead board-in connector to which the sensor leadis connected and a power-supply-lead board-in connector to which thepower supply lead is connected are disposed on the sensor substrate, thesensor-lead board-in connector is disposed between the bearing throughhole and the notch on the surface on an opposite side of the stator coreside of the sensor substrate, and the power-supply-lead board-inconnector is disposed on the surface on an opposite side of the statorcore side of the sensor substrate such that the power-supply-leadboard-in connector faces the sensor-lead board-in connector with thebearing through hole therebetween.
 5. The electric motor according toclaim 4, wherein the power supply lead is separated into two groups androuted to the notch along a periphery of the bearing through hole. 6.The electric motor according to claim 5, further comprising a substratepressing part attached to the surface on an opposite side of the statorcore side of the sensor substrate, the substrate pressing part includinga plurality of substrate pressing projections that come into contactwith the sensor substrate and press on the sensor substrate, wherein thepower supply lead is routed by being guided by the substrate pressingprojections disposed on the periphery of the bearing through hole. 7.The electric motor according to claim 6, wherein the substrate pressingpart includes a plurality of pins that are inserted into a plurality ofpin through holes provided in the sensor substrate.
 8. The electricmotor according to claim 5, further comprising a pair of notches for thepower supply lead to escape therethrough on a bearing through hole sideof the notch and on both ends of the notch in a direction orthogonal toa radial direction of the stator core, wherein the power supply lead isrouted from the power-supply-lead board-in connector to the notches forthe power supply lead to escape therethrough such that the power supplylead bypasses the bearing through hole and is then routed to the statorcore side of the sensor substrate through the notches for the powersupply lead to escape therethrough, and when viewed in plan from a sideopposite to the stator core side, the sensor lead is laid on the powersupply lead that is routed to the stator core side of the sensorsubstrate via the notches for the power supply lead to escapetherethrough.
 9. The electric motor according to claim 8, wherein aplurality of sensor leads are connected to the sensor-lead board-inconnector, a length between the notches for the power supply lead toescape therethrough is larger than a width occupied by the sensor leads,and the notches for the power supply lead to escape therethrough aredisposed outside a range that is occupied by the sensor leads.
 10. Anair conditioner comprising the electric motor according to claim
 1. 11.An electric apparatus comprising the electric motor according to claim1.